Blanket



Nov. 30, 1943. y A. L. BUTLER 2,335,642

I BLNKET Filed Jan. 11, 1943 igea WOOLEN F/L L ING Patented Nov. 30, 1943 UNITED STATES PATENT OFFICE BLANKET Application January 11, 1943, Serial No. 472,034

Claims.

The present invention relates to a new and improved construction in a domestic blanket, of the type used for bed clothing and the like. The invention consists in certain novel combinations of the materials from which the blanket is Woven andin novel structural features of the blanket, which are made possible by the new combination of materials employed.

A primary object of the invention is to produce a blanket which may be truthfully and accurately described as an all-Wool or 100% Wool blanket and which has greater Warmth and heat-insulating properties, for a given weight, than any other al1-wool or part-wool blanket previously known to the art.

A further object of the invention is to produce an all-wool blanket having a loftier nap for a given weight than prior art blankets, without sacrificing tensile strength in the Warp or the filling.

A further object is to produce an all-Wool blanket having such a nap and which has a greater tensile strength along both the warp and lling, than previously known blankets.

Another object of the invention is to produce a blanket characterized by a more tightly woven foundation fabric, thereby increasing its air and moisture impermeability and increasing its warmth.

Other and further objects and advantages of the invention will be explained as the description of the invention proceeds, and still others will be apparent to those skilled in the art, from a consideration of the specific embodiment set forth in detail below.

As stated above, the primary objects of the invention is to produce an improved blanket of al1-Wool construction. The purchasing public has developed a marked preference for blankets composed entirely of wool, based upon the firmly ingrained belief that all-Wool products are more luxurious, durable and Warmer for a given weight than products composed partly of wool and partly of cotton or similar fibres, generally considered to be inferior. Hence, all-wool blankets have been considered to be of the highest quality and have brought the highest prices.

In the past, all-wool blankets have been constructed of woolen threads in the warp and in the filling, and although such blankets have met with substantial commercial success and have enjoyed Wide popularity and public acceptance, they have had certain inherent disadvantages, due principally to the lack of high tensile strength in the woolen warp threads. The advantages of being able to designate blankets as all-wool or wool have, unti1 lately, outweighed these inherent disadvantages, however, and such blankets have been a standard article of commerce.

Recently, however, because of war-time restrictions on the use of woolen thread, blanket manufacturers have been forced to adopt cotton or other non-woolen material in the Warp, thereby making it impossible to designate blankets as composed of 100% wool.

The present invention has been developed as a result of the discovery that a certain wool product, which has not been restricted in its use by war-time conditions, forms an admirable substance for use in the Warp threads in the manufacture of domestic blankets. There is available in this country at the present time an adequate supply of mohair worsted thread, of the type formerly used in the filling or pile in upholstery fabrics, tapestry, fine rugs and the like. This mohair worsted is an exceedingly strong, finely spun, long fibered yarn, made from the fleece of the Angora goat by the worsted method of combing and spinning, as distinguished from the woolen method of making yarn from sheeps wool by carding and spinning. In mohair worsted thread or yarn, the fibres are of relatively great length and strength, are slippery or silky in structure and may be spun into worsted threads of extreme fineness, lightness and great strength.

As a result of the use of mohair worsted threads for the warp in my improved blanket, all of the above-mentioned principal objects are attained, as well as numerous unexpected advantages, among which the following may be noted.

Since mohair worsted is far stronger than woolen threads previously used in al1-wool blankets, it is now possible to use a much lighter, finer count in the warp. Hence, more ends (threads per inch in the warp) may be used, thereby increasing the tensile strength of the blanket along the warp and placing the Warp threads closer together. Moreover, these characteristics of the Warp make it possible to decrease the percentage ofthe total Weight of the blanket incorporated in the warp, and to increase the percentage of the total Weight Woven into the filling.

This allocation of a smaller percentage of the total weight in the warp and a larger percentage in the filling opens up vast fields for structural improvements in the manufacture of blankets and results in additional unexpected advantages in the new product as Well as in the manufacturing procedure.

First, a thicker lling thread and a filling having more picks (threads per inch in the weft) may be employed. The use of a heavier filling thread makes it possible to produce a longer or deeper nap in the napping operation, which results in increased warmth, increased wearing qualities and increased resistance to matting, felting and compacting influence, since the longer, deeper or loftier filling results in increased resiliency and rebounding characteristics. As is well known to those skilled in the blanket making art, as well as to housewives and the purchase public generally, a deeper or loftier nap gives a blanket an improved appearance andV feel and effects other highly desirable advantages.

Even though a deeper nap be pulled up from the filling, in accordance with the present invention, there is, nevertheless, a greater amount of thread left in yarn form in the filling, since, as pointed out above, the filling yarns initially employed are heavier and thicker than yarns employed in all-Wool blankets in accordance with the prior art. This unnapped yarn of increased volume or size remaining in the base fabric is a feature of major importance in the new blanket and accomplishes numerous advantageous results.

First, the unnapped residue in the lling, being larger and heavier than the residue in all-wool blankets of the prior art, greatly increases the tensile strength of the blanket along the lling.

Second, the wearing characteristics of the blanket are likewise increased, since the larger remaining threads will not break or Wear through as quickly as the smaller ones of the prior art.

Third, the fibres in the nap are more rmly anchored in the base fabric and will not readily wear away or become detached in use, since only the longer libres in the lling are pulled up in the napping operation, and these ibres are more firmly attached at their inner ends to the nlling threads of larger size. Hence, the blanket of the present invention has decreased fibreshedding properties.

Fourth, the blanket is of increased warmth because of the larger size of the lling threads left in the blanket and because a tighter and. more compact inner body or base fabric is provided.

Fifth, the air permeability of the blanket is decreased because of the tighter foundation weave and the increase in the size of the filling threads. Likewise, the water and moistureproof characteristics of the blanket are increased by the same relation of parts.

The blanket of the present invention has greatly improved laundering qualities and is less subject to shrinkage than any all-wool blanket of comparable weight produced in accordance with the prior art. These advantages flow from the following facts:

First, mohair fibres are relatively straight, silky and smooth, and inherently are less subject to shrinking tendencies than wool fibres. Moreover, mohair worsted threads shrink less than woolen threads.

Second, mohair bres are non-felting and will not mat or felt with the woolen filling. In the combination disclosed herein, the mohair bres actually serve as separators for the woolen fibres and keep them apart, thereby preventing the felting, matting and shrinking that other.,- wise might be expected.

Third, the increased number of ends and picks' employed in the new blanket produces a more compact inner body, which inherently shrinks less than a more loosely woven body.

The blanket of the present invention, characterized by the inclusion of a mohair worsted warp results in additional, important and unexpected advantages in the manufacturing operations, among which the following may be noted:

First, the mohair worsted threads are far stronger than woolen threads of the same or even considerably greater size. Hence, the threads are less likely to break when being drawn from the creel and wound upon the warp reel, as well as in the warp beam formation. The improved, non-breaking characteristics of these warp threads are particularly evident in the loom, and it has been noted in actual practice that interruptions of the operation of the loom, due to warp thread breaks, are substantially completely, if not entirely, eliminated.

SecondJ the use of heavier threads or yarnsin the filling and more picks inthe filling, both made possible, as explained above, by theuse of mohairworsted threads in the warp, greatly facilitates the napping operation. The fabric of the present invention need be passed through the napping, machine only about one-half as many timesas previously, yet a nap as deep or deeper than that produced with cloth of the prior art may be pulled up. This phenomenon probably may be. explained by the fact that the larger and fuller filling threads make it much easier toV pull up a, nap of the desiredv height.

Third, the loss of weight in the wovenmaterial, which inevitably results in dyeing, fulling, washing and napping is greatly decreased, as compared to all-Wool and part-Wool blankets produced in accordance with the prior art. It has been noticed in commercial operations under the present invention that practically no loss of nbres in the form ofV flock is suffered in thenapping operation.

The decreasein the loss of dyeing, fulling and washing is probably due to the fact thatthe iilling threads are larger and inherently stronger, so that the individual fibres in the filling threads are more firmly anchored and are less easily dislodged or detached, bythe rather rough handling towhich the fabric is subjected during these operations.

The very substantial decrease in lossin the napping is undoubtedly due. toy the factY that a better surface for napping is` provided in the fabric. That is to say, the napping machinehas more threads and larger threads to operateupon. Hence, less fibres are pulled up from each thread, andless are completely dislodged or-.broken and thereby wasted.

In practice, it has been found; that the total loss in weight in the fabric, from thefloom until the fabric is` cut into finished blanket sizes, has been decreased from 16%, which wasconsidered unobjectionablewith all-wool blankets in the prior art, to 7% or less wththe new fabric,r This decrease in loss of weight in the manufacturing operation is, of course, a factor of major. importance in large blanketV mills, sincethe loss is substantially 'a complete waste, and such material as can be salvaged in the form of flock has little value.

Finally, the newk fabric has` greatly improved dyeingcharacteristics, asgcoinpared withpriorart blankeisin which@ wool filling wa'swovenupqp a cotton, silk or rayon warp, since the mohair Warp has the same dyeing characteristics as the Wool filling and may be dyed in the piece with the same results as an all-Wool blanket having a woolen warp. It is well known to those skilled in the dyeing art that cotton, silk, rayon and other artificial fibres react to dyes differently from wool yarns or threads. Therefore, when such bres are used in the warp, special measures must be employed to dye the warp the same color as the filling. Otherwise, a spotty, mottled, unattractive fabric will be produced. Mohair, however, being an animal libre from the Angora goat, has many of the characteristics of wool, and reacts to dye in the same manner, with the result that the woven fabric of the present invention may be dyed in a single operation by the standard wool dyes and a satisfactory product produced.

. The accompanying drawing constitutes a conventional, diagrammatic, somewhat exaggerated showing of a fabric produced in accordance with this invention.

In the drawing,

Figure 1 is a plan view of the fabric, prior to napping, and

. Figure 2 is a cross-section taken along line 2 2 of Figure 1. The relatively small and tightly spun mohair worsted warp threads are indicated at Il] and the larger woolen filling threads at Il. It must be understood that the relative spacing of the warp and filling threads in the accompanying drawing is diagrammatic only and that the invention is not limited to the weave most clearly shown in Figure 2. This weave, however, is well adapted for use in the present invention and produces an entirely satisfactory blanket. Reference is made to Patent No. 2,090,547, Neaves, August 17, 1937, for a more complete description of the structure of the preferred weave.

After describing a specific example of a blanket fabric in accordance with the invention of the present application, a comparison will be made with a high quality, prior yart all-Wool blanket of like weight.

In producing a four-pound blanket of a size of 72 x 90 inches, the warp threads I0 may be a twoply, fifteen count (worsted count) thread, otherwise designated as fourteen out. This grade of mohair worsted weighs ,83 grains to 50 yards. In a 72 inch blanket, the warp threads may be arranged to provide 2250 ends (31.25 ends per inch).

The filling may be a woolen yarn, 81A; cut, weighing 140 grains per 50 yards. The filling may be woven with 34 picks per inch, providing a total of 3060 picks in a 90 inch blanket.

With this relation of parts, only substantially 30% 0f the Weight of the blanket goes into the warp and the remaining 70% is included in the filling. Even though a deeper, loftier nap is pulled up, the blanket has the remarkable strength characteristics of a 90 pounds grab test along the warp and 40-45 pounds along the iilling. These strength tests, conducted in accordance with the standards of the Division of Textiles and Clothing of the Bureau of Home Economics of the Department of Agriculture are greatly in excess of any all-wool blankets of comparable weight heretofore known.

A typically high-quality 4-pound blanket of the size indicated above, 72 x 90 inches, heretofore produced by applicants assignee, was constructed of 40% of the weight in the warp and 60% of the weight in the lling. The warp was constructed of 9.3 cut woolen yarn (125 grains to 50 yards) twisted more tightly than the filling yarn. The warp had 1748 ends (substantially 24.27 ends per inch). The lling was woolen yarn 91/3 cut (125 grains per 50 yards) and was woven with 32 picks per inch.

Although blankets constructed in accordance with the latter specifications were entirely satisfactory to the trade and enjoyed very substantial commercial popularity, the improvements resulting from the present invention become apparent when the tensile strengths are compared The al1-wool blanket described above, with a woolen Warp, had an average tensile strenth along the warp, when tested by the grab test referred to above, of 35 pounds and along the filling of only 24 pounds, as compared with 90 pounds and 40-45 pounds in the new blanket.

The blanket of the present invention, as pointed out above, has very pronounced increased resistance to shrinkage. The standards laid down by the Bureau of Home Economics referred to above after three washings, in accordance with the instructions of that bureau, are 10% along the warp and 10% along the filling.

Extensive tests of the all-wool, woolen warp blankets described above show an average maximum shrinkage, after three washings of 8% in both directions. The blankets of the present invention, tested many times, have shown an average maximum shrinkage, after three washings of 3.23% along the warp and 2.77% in the direction of the filling.

The advantages of the new blanket over the best quality all-wool blankets of comparable weight, produced in accordance with the prior v art, are real, substantial and important. The superior wearing qualities, which result from the increased tensile strength and from the increased length of the nap (more firmly anchored to a more tightly woven base fabric) are suflicient to cause the new blankets to supplant the old ones.

The increase in warmth, resulting from the loftier nap and the more tightly woven foundation fabric is an item of maximum importance to the purchasing public.

The advantages in the manufacturing operations described above, which flow from the use of a mohair worsted warp, produce economies and savings which are of great importance to large blanket manufacturing concerns.

Aside from these advantages, the present invention has important practical virtues at the present time, since a stable source of supply of the material from which the warp is made is available in this country, wholly unrestricted by rationing or other regulations by War-time agencies of the Federal Government. Hence, the blanket of the present invention, although using non-critical materials, may be truthfully termed an all-wool or wool blanket. As explained above, this designation has a very substantial sales appeal and is of importance to blanket manufacturers.

Although the invention has been described with considerable particularity in this specification, it must be understood that it is not limited to the details of construction or proportions of parts set forth above. Moreover, the invention is not restricted to use in the manufacture of domestic or household blankets, since the fabric produced in accordance with the invention obviously has a utility in other fields. All constructions coming within the scope of the appended claims and their equivalents are intended to be included within the invention.

Ifclaimt' 1. Av blanket comprising a mohai'r'worsted.y

Warp and.- a` Woolen yarn:l lling', characterized' in? thatthe Warp. includes substantiallyOoY or lessv and the weft substantially 70% or morezoffthe total Aweight of the blanket.

2'. AnY all-Wool blanket,.comprisin'g=. a. mohair` Worsted-Lvvarpf and a woolen yarn lling,Y char.v`-

acterized bytheuse in' the. warpof. a nerecount.

thread,dan increaseJin thenumberv offends,xan'd an increased tensile strengt1f`rinthe@Warpfand` lling, as compared with all-wool blankets-of; like weight having Woolen Warps..

3. An all-Wool blanket comprisingY a'. mohair characterized in that, as compared to-Yall-vvoolI blankets of like Weight having Woolen Warps, it` has greater tensile strength in the Warp and.v in the filling, has a finer count thread and more ends in the Warp and a smaller percentage of the total weight of the blanket in the Warp, and has a heavier count Wcolen yarn and more picks in the filling and a larger percentage of the total Weight in the llingand the nap.V

5. An all-wool blanket comprising amohair Worsted warp and a Woolen yarn filling, characterized in that, as compared to all-wool blankets of like weight having Woclen Warps, it has a ner yet stronger Warp and afheavier Woolen lling including more picks in the lling, a loftier nap, and larger threads remaining unnapped-in the filling in thread form, thereby producing increased Warmth and increased wearingproperties.

6. An all-Wool blanket comprising a mohair Worsted Warp, a Woolen yarn lling and a napl of substantial height pulled up `fromthe lling only', characterized in that, as compared to all-Wool blankets of like weight having woolen'Wa-rps; it has more ends in the Warp and more picks inthe filling, thereby producing amore tightly Woven basenhas a greater` tensile strength in the Warpl and in thev fillingand hasaJargenpercentageloftheftotaflf Weight lin thefillingf and napand aV smallerl percentage of. totalV Weight- Y inthe warp. 7. Anj all-Woolf` blanketf comprising a mohair Worstedwarp,"y a Woolen vyarn lling. and. ai nap.I of: substantial,k height pulled. upI from the.,r lling; only, characterizedin` that,y ascompared to al1-4 WoolA blankets; off like weiglit-` having.'l Woolen: Warps', it` hast morer ends inthe-warp andJ morey pickseinxthe` lling;.therebyproducing a more tightlytwoven ibase; and-has a larger, lllingfthreacl` remaining. inv thread form in the base. after napping, thereby: increasing, thetensilastrength` along' the lling;

8. An. all-Wooll blanket. comprising mohair worsted. warp threads and Woolen, illingr threads,`

cl'lara'cterized by increased tensile' strength in the Warp and lling` and bythe presence in the Warp of;v more ends than. in. conventional all- Wool blankets of thesame Weightfhavingfwoolen Warps, and by a larger filling yarn and more picks in the lling, and by a loftiernap andY a larger remainingl lling thread.

9. An all-Wool blanket comprising-substantial` ly 30% or lessof the Weight of the blanket in the Warp and substantially 70% or. more in the lling, saidvvarp comprising relatively ine mohairlworsted threads-and relatively heavy Woolen yarn inthe lling, saidblanket having a napl of substantial height` pulled up from the lling and being characterized by greater tensile 

